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Old 03-10-2021, 03:42 PM   #41
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Routed the door handle recesses using the patterns created in Post # 36.

Applied epoxy to raw wood to prevent moisture intrusion.

Test fit - perfect!
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Old 03-10-2021, 03:51 PM   #42
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Using a MDF pattern, routed the landing for the 3/8" plywood that will be mounted to the inside of the window opening to hold the glass in place. You can see the 3/8" plywood inner panels in the background of the pictures. Those were routed to shape with the patterns created earlier.

The finished routed recess - Pic 2

Trial fitting the 3/8" plywood on the inside of the window - Pic 3

Test fit new glass - Pic 4. The black rubber spacers represent the future thickness of the sealant/adhesive. They will insure that the sealant/adhesive will be uniform thickness.

The tempered window glass was ordered from a glass shop, who used
the pattern I supplied - Post #3

With the inner 3/8" plywood test fitted - pic 5

The difference in color of the plywood is because 3/8" was only available in Aquatek Plywood. The lighter color plywood on the rest of the door is Sande/Virola Plywood. Both are marine plywoods.
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Old 03-13-2021, 01:23 AM   #43
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Very nice work! I appreciate your attention to detail.
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Old 03-13-2021, 11:10 AM   #44
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Very nice work! I appreciate your attention to detail.
Thank you!
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Old 03-13-2021, 11:22 AM   #45
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Very satisfying.
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Old 03-13-2021, 11:53 AM   #46
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Very satisfying.
Yes, it is very satisfying to do projects like this.
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Old 03-14-2021, 03:10 PM   #47
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Applied a coat of epoxy on the routed wood to prevent moisture intrusion. Pic 1

And a precoat of epoxy to the inner panel before glassing. Trial fitting to make sure epoxy did not alter fit. Pic 2

Built risers out of scraps for the inner panels to raise them off the table during glassing. Pic 3

Inner panels on risers with 5 oz glass cloth draped ready for epoxy. Pic 4

Applying epoxy to the cloth with a brush. Pic 5

The epoxy is spread with a spreader and rolled with a laminate roller to bring excess epoxy to the surface to be squeegeed away. Pic 6

The goal is to not have excess epoxy under the cloth. The purpose of the fiberglass cloth is not strength but as a way to insure uniform epoxy thickness, puncture resistance and a smooth hard surface for paint. Any excess epoxy under the cloth lifts the cloth and creates an uneven surtace requiring fairing and more sanding than necessary. Plus the possibility of sanding through the glass cloth at the high spots.

After the epoxy hardens, the cloth will be trimmed and the weave filled with epoxy.
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Old 03-14-2021, 03:57 PM   #48
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Old 05-01-2021, 04:28 PM   #49
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Painted the exterior side of the doors prior to the installation of the window glass.

Decided to try spray painting the doors with the System Three WR LPU water based polyurethane paint for the first time. I usually roll and tip WR LPU but I wanted a sprayed on look on the doors. Purchased a Graco Airless Paint Sprayer and erected a temporary paint booth under a deck.

The airless sprayer did an excellent job producing a smooth finish without any orange peel. Experimented with various sprayer settings and thinning of the paint with water.

The sprayer produced very little overspray and no odor so did not have to wear a respirator.
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Old 05-01-2021, 04:36 PM   #50
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Painted the inner panel around the glass opening prior to installing it to make masking and painting the inside of the door easier.

Installed window glass using 3M Auto Glass Urethane Windshield Adhesive. The adhesive was applied to the glass and the glass set in the routed recess. The glass sits on small rubber pads (Post 42 pic #4) to maintain an even sealant thickness and to center the glass in the recess.

For the inner panel, 3M Urethane Adhesive was applied around the perimeter of the glass and the inner panel glued to the door with epoxy around it's perimeter.

Temporary screws were used to hold the panel in place until the epoxy cured and the screws were removed.

The urethane skins over quickly so did not have time to take pictures of that process.

The glue line was faired and sanded.
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Old 05-01-2021, 04:48 PM   #51
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The inner side is coated with additional epoxy before painting.

View of the painted exterior side of doors after glass installation.

Paint the inner side and I'm done!
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